Service Electrical

Battery Warning

WARNING: Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Service the Battery Safely

c CAUTION: Avoid injury! Battery electrolyte contains sulfuric acid. It is poisonous and can cause serious burns:

• Wear eye protection and gloves.

• Keep skin protected.

• If electrolyte is swallowed, get medical attention immediately.

• If electrolyte is splashed into eyes, flush immediately with water for 15-30 minutes and get medical attention.

• If electrolyte is splashed onto skin, flush immediately with water and get medical attention if necessary.

The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke near battery.

• Wear eye protection and gloves.

• Do not allow direct metal contact across battery posts.

• Remove negative cable first when disconnecting.

• Install negative cable last when connecting.

Checking Battery Electrolyte Level

NOTE: Add only distilled water to replace battery electrolyte.

1. Park the machine safely. (See Parking Safely in the SAFETY section.)

2. Remove battery cell caps. Make sure cap vents are not plugged.

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3. Check electrolyte level. Electrolyte (B) should be approximately halfway between bottom of filler neck (A) and top of plates (C).


IMPORTANT: Avoid damage! Do not overfill battery. Electrolyte can overflow when battery is charged and cause damage.

4. Add only distilled water if necessary.

5. Install battery cell caps.

Removing and Installing Battery

Removing:

1. Park the machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood and latch open.

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3. Pull out on grille and disconnect two springs (A) to remove grille.

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4. Disconnect black negative (-) cable (B) from battery first.

5. Slide red positive terminal cover (C) back and disconnect red positive (+) cable (D).

6. Remove battery hold-down.

• Remove hex nuts (E) and bracket (F).

7. Remove battery.

Installing:

1. Install battery into machine.

2. Check manifold caps to be sure vent holes are open.

3. Install battery hold-down assembly. Do not overtighten.

4. Connect positive (+) cable to battery positive (+) terminal first, then negative (-) cable to battery negative (-) terminal.

5. Apply spray lubricant on battery terminals to help prevent corrosion.

6. Install front grille.

7. Lower hood.

Cleaning Battery and Terminals

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Disconnect and remove battery.

3. Wash battery with solution of four tablespoons of baking soda to one gallon of water. Be careful not to get the soda solution into the cells.

4. Rinse the battery with plain water and dry.

5. Clean terminals and battery cable ends with wire brush until bright.

6. Install battery.

7. Attach cables to battery terminals using washers and nuts.

8. Apply spray lubricant to terminal to prevent corrosion.

Using Booster Battery

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke or have open flame near battery.

• Wear eye protection and gloves.

• Do not jump start or charge a frozen battery. Warm battery to 16°C (60°F).

• Do not connect the negative (-) booster cable to the negative (-) terminal of the discharged battery. Connect at a good ground location away from the discharged battery.

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A - Booster Battery

B - Disabled Vehicle Battery

1. Connect positive (+) booster cable to booster battery (A) positive (+) post (C).

2. Connect the other end of positive (+) booster cable to the disabled vehicle battery (B) positive (+) post (D).

3. Connect negative (–) booster cable to booster battery negative (–) post (E).


IMPORTANT: Avoid damage! Electric charge from booster battery can damage machine components. Do not install negative booster cable to machine frame. Install only to the engine block. Install negative booster cable away from moving parts in the engine compartment, such as belts and fan blades.

4. Connect the other end (F) of negative (–) booster cable to a metal part of the disabled machine engine block away from battery.

5. Start the engine of the disabled machine and run machine for several minutes.

6. Carefully disconnect the booster cables in the exact reverse order: negative cable first and then the positive cable.

Replacing Light Bulbs

Headlight Bulb


IMPORTANT: Avoid damage! Do not touch glass headlight bulb with bare skin or bulb may fail prematurely. Use gloves or a cloth when inspecting or replacing the bulb.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise hood and latch open.

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3. Disconnect wiring harness (A) from headlight bulb connector (B).

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4. Pull back rubber protector (C) from assembly. Rotate headlight bulb assembly (D) left 1/3 turn and remove from headlight housing socket.

5. Install new headlight bulb assembly into housing socket and rotate right 1/3 turn into a locked position.

6. Replace rubber protector (C).

7. Connect wiring harness to headlight bulb connector.

8. Check lights.

9. Lower hood.

Taillight Bulb

NOTE: Taillight can be serviced by removing the rear assembly lens.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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2. Remove two screws (A) and lens from the taillight assembly.

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3. Push and turn bulb (B) to remove.

4. Push new bulb into socket and rotate to lock in place.

5. Check light operation.

6. Install lens.

Warning Light Bulb

1. Park machine safely. (See Parking Safely in the SAFETY section.)

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2. Remove three screws (A) and lens (B) from the warning light assembly.

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3. Push down and rotate bulb (C) to remove.

4. Push new bulb into socket and rotate to lock in place.

5. Check light operation.

6. Install lens.

Adjusting Headlights

1. Park machine safely on a level surface at least 5m (15ft.) away from a flat vertical surface. (See Parking Safely in the SAFETY section.)

2. Turn on head lights.

3. Raise hood.

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4. Turn head light screw (A) to adjust light beam up or down.

5. Repeat procedure for opposite headlight if adjustment is required.

6. Lower hood.

Replacing Instrument Panel Light Bulb

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise and latch hood.

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3. Remove five screws (A) from console panel. Remove panel.

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4. Remove six instrument panel screws (B).

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5. Carefully raise instrument panel (C).

6. Identify defective bulb location and remove bulb holder (D) from instrument panel socket.

7. Pull defective bulb from socket. Do not twist.

8. Push new bulb (E) into socket.

9. Install bulb holder over bulb and into instrument panel.

10. Check lights.

11. Install instrument panel.

12. Install console panel.

Replacing Fuses


IMPORTANT: Avoid damage! The electrical system may be damaged if incorrect replacement fuses are used. Replace the bad fuse with a fuse of the same amp rating.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise and latch hood.

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3. Remove cover (A) from fuse holder.

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4. Identify fuses:

• 15 Amp Fuse (B): Headlights

• 5 Amp Fuse (C): Taillights

• 15 Amp Fuse (D): Warning Lights

• 10 Amp Fuse (E): Flood Lights

• 15 Amp Fuse (F): Spare

• 3 Amp Fuse (G): Seat Switch

• 3 Amp Fuse (H): Control Box

• 10 Amp Fuse (I): Indicator Lamps

• 10 Amp Fuse (J): Spare

5. Pull defective fuse from socket.

6. Push new fuse into socket.

7. Install cover to fuse holder.

8. Lower hood.

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